BLANK NESTING

This function enables the user to nest the blank in a strip. This function may be invoked by clicking the BSE/DEVELOPMENT/BLANK NESTING.  Figure 7.5.11 shows the types of nesting options available in the BLANK NESTING menu.

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Figure 7.5.11  Blank Nesting Types

ONE-UP NESTING image740

Enables the user to generate the nesting result in one row.

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Figure 7.5.12  One-up Nesting

 

TWO-UP NESTING image751

Enables the user to generate the nesting result with two identical blanks using a common orientation.

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Figure 7.5.13  Two-up Nesting

TWO-PAIR NESTING  image763

Enables the user to generate the nesting result with a pair of identical blanks in opposite orientation.

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Figure 7.5.14  Two-pair Nesting

MIRROR NESTING image764

Enables the user to generate the nesting result by mirroring the blank.

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Figure 7.5.15  Mirror Nesting

MULTI BLANKS NESTING image765

Enables the user to generate the nesting result using multiple blanks with different size and shape.

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Figure 7.5.16  Multi blanks Nesting

RECTANGLE NESTING 7_5_17

Enables the user to generate the nesting result by embedding the blank in rectangle.

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Figure 7.5.17  Rectangle Nesting

PARALLEL NESTING 7_5_para

Enables the user to generate the nesting result by embedding the blank in parallelogram.

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Figure 7.5.18  Parallel Nesting

ISOSCELES TRAPEZOID NESTING 7_5_tap

Enables the user to generate the nesting result by embedding the blank in isosceles trapezoid.

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Figure 7.5.19  Isosceles Trapezoid Nesting

TRAPEZOID NESTING 7_5_ge-tap

Enables the user to generate the nesting result by embedding the blank in trapezoid.

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Figure 7.5.20  Trapezoid Nesting

ARC NESTING 7_5_arc

Enables the user to generate the nesting result by embedding the blank in arc.

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Figure 7.5.21  Arc Nesting

 

Examples of blank nesting are illustrated in Figure 7.5.12 to Figure 7.5.21. A detailed description of each function is given in the following section.

7.5.6.1  ONE-UP NESTING 

This function enables the user to generate the nesting result in one row. The dialog box is shown in Figure 7.5.22.

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Figure 7.5.22  One-up Nesting dialog box

SETUP

In the SETUP tab, the user can select Input Unit, define Blank Outline, and set parameters such as Thickness, Density, Edge Width, Bridge Span, and Addendum size.

NESTING TYPE

   Form Nesting Type

   This indicates the nesting functions in the first row in the GUI window, including one-up nesting, two-up nesting, two-pair nesting, mirror nesting and multi blanks. The user is allowed to select one of these types for nesting.

   Draw Nesting Type

   This indicates the nesting functions in the second row in the GUI window, including rectangle nesting, parallel nesting, isosceles-trapezoid nesting, trapezoid nesting and arc nesting. The user is allowed to select one of these types for nesting.

 

OPTIMIZATION

There are two types of nesting optimization. One is to use the material utilization as optimization target to maximize the use of strip. The other is to use the material for nesting as optimization target to minimize the strip price for nesting.

   Max Utili.

   This is a commonly used optimization type, which is to maximize the material utilization in the nesting process.

 

   Min Price

   The strips used for nesting have different prices. During nesting calculation, besides the material utilization, the production cost will also be considered so that the material price could be minimized for nesting. Once this option is toggled on, the Price page will be enabled.

 

   Form Type

   After the user selects one optimization target and toggles on this option, all the nesting functions except multi blanks in the first row will be highlighted. The program will automatically calculate all the highlighted nesting types and save the calculation results corresponding to each nesting type in the result list for the user to browse and compare the difference.

 

   Draw Type

   After the user selects one optimization target and toggles on this option, all the nesting functions in the second row will be highlighted. The program will calculate all the nesting types in the second row, and save the calculation results corresponding to each nesting type in the result list for the user to browse and compare the difference.

 

UNIT

Metric

Enables the user to define the nesting setup parameters in metric unit.

 

English

Enables the user to define the nesting setup parameters in inch unit.

 

OUTLINE

This parameter is used to define the Blank Outline. Click on the Blank Outline (Undefined) button in Figure 7.5.22, the program displays the SELECT LINE dialog box, and prompt the user to select lines. After the Blank Outline is selected, the button name is changed to Blank Outline.

MATERIAL

The user can define blank material using two methods.  In first method, the user can click on the MATERIAL button to open the MATERIAL dialog box. The user may choose to create a NEW material or IMPORT a specific material from the MATERIAL dialog box. Once the material is defined, the density of material is automatically displayed in the nesting window. The user proceeds to define part thickness. Another method is by entering the THICKNESS and DENSITY directly in the corresponding input data fields.

Thickness

Enables the user to define blank thickness.

Density

Enables the user to define density of material.

 

PARAMETERS

This function is used to set the edge width and bridge span. The newly added two options are used to specify the determination of the initial edge width and bridge span. One is read in from the config file; the other is from the CSV file.

By Default

This option enables the user to read in the initial edge width and bridge span from the dynaformdefault.config file.

By Csv file

This option enables the user to read in the initial edge width and bridge span from the NestingParameter.csv file which is in the installation directory folder. This file sets the edge width and bridge span according to the perimeter of the defined outline. It also allows the user to modify and edit the values.

Edge Width

Allow the user to define the gap between blank outline and strip edge.

Bridge Span

Allow the user to define the gap between parts.

Select Blank

This option enables the user to choose between multiple blanks to assign different or common addendum sizes.  Please note that this option is only available for nesting options with more than one blank outline.

Addendum

Allow the user to expand the selected blank outline.

 

The parameters are shown in Figure 7.5.23.

Figure 7.5.23  Edge Width, Bridge Span and Addendum

CONSTRAINTS

This function enables the user to constrain the dimension of the strip and the angle of blank relative to the strip direction. The tab is illustrated in Figure 7.5.24.

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Figure 7.5.24  Constraints

COIL DIMENSION

LENGTH

Fix Length is used to restrict the strip length. The user can click on  to calculate the strip length. After CALC button is hit, the Calculator dialog box illustrated in Figure 7.5.25 is displayed. The UNIT in the dialog box depends on the UNIT selected in blank nesting. The user can select ID and OD value, which is configured by coilinfo.txt file in installation directory. After these two values are selected, the strip length will be displayed in the LENGTH field.

Figure 7.5.25  Calculator dialog box

STEP OPTION

X-Y STEP

This function is used to set the translation step of blank along X and Y directions. During nesting calculation, the program will move the blank according to the defined translation step within the defined range to obtain a series of results. The default X-Y Step is 10.

ANGLE STEP

This function is used to set the angle step of blank rotating about the center. The default angle step is 2 degrees. During nesting calculation, the program will rotate the blank according to the defined angle step within the defined range to obtain a series of results.

RANGE OPTION

This option uses the range values to constrain the parameters such as rotation angle, width, pitch, cut-off profile angle, and cut-off profile arc radius.

ANGLE

Min./Max.: Use an angle with a certain range to constrain the blank rotation and strip width. After entering the minimum and maximum values of angle, blank nesting calculates a series of results according to the defined range of the rotation angle.

WIDTH

Constrain the width of the strip or sheet.

The width range is used as the width constraint. The user defines the allowable range of the blank width (Min and Max). Blank nesting calculates a series of results according to the defined range of the width.

PITCH

Constrain the feeding of coil.

Cut-off die

L Angle: The angle between the left side of rectangle, parallelogram and trapezoid with the positive direction of X axis. Use an angle value within a certain range to constrain the shape of the parallelogram, isosceles trapezoid and trapezoid profiles. After entering the minimum and maximum values of angle, blank nesting calculates a series of results accordingly.

R Angle: The angle between the right side of trapezoid and the positive direction of X axis. Use an angle value within a certain range to constrain the shape of trapezoid profile. After entering the minimum and maximum values of angle, blank nesting calculates a series of results accordingly.

Radius: The radius of the arc profile. Use an angle value within a certain range to constrain the shape of arc profile. After entering the minimum and maximum values of angle, blank nesting calculates a series of results accordingly.

BLANK OPTION

Fix Angle is used to specifically define a constant rotation angle.

Fix Pitch is used to specifically define a constant pitch.

Fix Width is used to specifically define a constant width.

Width >Pitch: During nesting, width is greater than pitch. This option will automatically change to Width >Pitch*0.5 to constrain part when the user selects Two Pair, Mirror, Isosceles-trapezoid and Trapezoid.

APPLY

Click on the Apply button illustrated in Figure 7.5.24 to calculate the nesting result and show it on the screen according to the current blank position, as illustrated in Figure 7.5.26. The user may also click the Position button to adjust the blank and blank profile. Click the Save button to save the result in the Nesting Result.

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Figure 7.5.26  The Result of One-up Nesting

Price

The Price page can only be enabled when the user selects Min Price as the optimization type on Setup page, as illustrated in Figure 7.5.27. The Price page shows the material name and density of the outline defined on the setup page, and provides the price list of material. It allows the user to perform create, import or delete operations.

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Figure 7.5.27  Price page

Material

Material shows the material name defined on Setup page and cannot be modified.

Thickness shows the material thickness defined on Setup page and cannot be modified.

 

Price List

In the installation directory folder, there is a price.csv file which is a table made according to different thickness and width. The initial price values in the price list are read in from this file, and the user is allowed to modify and edit this file.

   New  allows the user to create a line at the end of the list, but the new line is not allowed to be inserted into the middle of the list. After clicking this button, the program will automatically add a new line and the price value is same with the last line.

   Delete  allows the user to delete any line in the list.

   Import  allows the user to import the modified price list which format is Csv.

   Extra Cost allows the user to enter the extra material price.

Scrap Cost allows the user to enter the scrap price.

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Figure 7.5.28  Result of Blank Nesting

RESULT

Blank nesting calculates a series of results according to input constraints. The user may edit the number of decimal digit by choosing the number from the Decimal digits combo box. The user may select any result from the list to display the corresponding constraints in the Result tab illustrated in Figure 7.5.28.

NOTE: The user can not change type of nesting or unit system when nesting result is obtained.

l  Decimal digits

This function enables the user to set the decimal digits of result. The default is three decimal places.

l  Output Nest Report

This function enables the user to output the nesting result in HTML format. The interface of the Output Nesting Report is illustrated in Figure 7.5.29.

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Figure 7.5.29  The Output Nesting Report dialog box

Click Apply button to output the nesting result. The nesting report will be presented automatically in .htm format.

DATE

Display date of the nesting report.

FILE NAME

Enable the user to assign a file name (.htm) and the file path to save the current nesting report.

BLANK OUTLINE COLOR

Enable the user to change color of the blank outline.

UNIT

Display current unit system in nesting report.

PRODUCTION VOLUME / PER COIL

Enable the user to select PRODUCTION VOLUME or PER COIL for cost calculation.

PRODUCTION VOLUME (×1000)

Enable the user to define production volume.

COIL LENGTH

Display coil length defined in Constraints.

BASE MATERIAL COST

Enable the user to define base material cost.

EXTRA MATERIAL COST

Enable the user to define extra material cost.

SCRAP VALUE COST

Enable the user to define scrap value cost.

CONSUMABLES COST

Enable the user to define consumable cost.

COMMENTS

Enable the user to write comments in the nesting report.

Click on the Apply button to save the current nesting report as.htm file. Then, the file automatically displayed in the default web browser (PC with Windows operating system). A sample nesting report is illustrated in Figure 7.5.30.

NOTE: In the report, only when the user calculates the area of part will there be values export for Product Weight and Yield Ratio options. The values for these two options are obtained according to the calculated part area and the defined part material.

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Figure 7.5.30  A typical nesting report

l  Calculate 3D Trim Line

The user uses MSTEP to estimate the outline of blank part. After the calculation, the user will obtain the blank outline. Select Draw Nesting Type for nesting calculation and then enter the Position interface to scale Pitch , which will activate this button. After the Pitch is scaled, the program will automatically project the adjusted 2D line onto the 3D product part, namely the 3D trim line. Refer to Section 7.5.6.6.

l  Calculate Addendum

This button can only be activated when the user selects Draw Nesting Type. Refer to section 7.5.6.6 for detailed description.

 

NESTING RESULT

        This option enables the user to store the different nesting results conveniently. The user may start recalculation by adjusting some parameters, or switch to a different nesting type without exiting the Nesting dialog box, and compare the result after adjustment with the stored one. Click the Save button to save the nesting results in this list and the results will be named using the nesting type. Click the Load button to show the selected result from the current list in view area. Click the Remove button to remove the nesting result from the list, as illustrated in Figure 7.5.31.

result

Figure 7.5.31  Nesting result list

7.5.6.2 TWO-UP NESTING

This function enables the user to generate the nesting result of two identical blanks with common orientation. The setting of Setup and Constraint in this function is similar to those described in the One-up Nesting. Refer to Section 7.5.6.1 for a description of commonly used parameters.

 

The Position button and Save button are activated after the nesting calculation is completed. This Position button enables the user to adjust the relative position between two blanks by moving, rotating, and mirroring the blank. Click on the Position button to open the Blank Position dialog box illustrated in Figure 7.5.32.

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Figure 7.5.32  Auto Position dialog box

 

X-Y STEP

This function allows the user to set incremental value in X and Y direction for transformation. The default X-Y step is 10. The setup of parameters is similar to the one in the Constraints page.

 

ANGLE STEP

This is the angle increment for blank rotation. The default angle step is 2 degrees. The setup of parameters is similar to the one in the Constraints page.

 

SELECT BLANK

This function enables the user to select master blank and slave blank respectively, to perform operations such as translation, rotation and mirroring, and adjust the position between blank nestings manually for multiple parts nesting. Once a blank is selected, the outline of this blank turns to grey. Since Master Blank mainly controls the pitch size during nesting, the adjusting button can only be enabled after selecting the Slave Blank option from the list.

 

MANUAL

This function enables the user to manually position the blanks through translation, rotation and mirroring.

 

TRANSFORMATION

 

up Move selected blank outline in positive X-axis direction according to incremental distance.

down Move selected blank outline in negative X-axis direction according to incremental distance.

right Move selected blank outline in positive Y-axis direction according to incremental distance.

left Move selected blank outline in negative Y-axis direction according to incremental distance.

 

Rotation

 

rot2 Rotate selected blank outline clockwise by incremental angle.

rot1 Rotate selected blank outline counter-clockwise by incremental angle.

 

MIRROR

mir1 Mirror the selected blank about Y axis.

mir2 Rotate the selected blank 180 degrees about X axis, and then mirror it about Y axis.

 

PARAMETERS

this function is used to show the currently adjusted parameters. The user may also enter values directly. According to the adjusted parameters, the program automatically calculates and shows the nesting results, width, pitch and utilization.

L Angle: This option is only available when parallel nesting, isosceles trapezoid nesting, and trapezoid nesting are selected. It is used to show the current angle when adjusting the cut-off profile shape.

 

R Angle: This option is only available when trapezoid cut-off profile nesting is selected. It is used to show the current angle when adjusting the cut-off profile shape.

 

Radius: This option is only available when arc nesting is selected. It is used to show the current radius of arc when adjusting the cut-off profile shape.

 

Angle: Shows the current angle of blank rotation when adjusting the blank position.

 

Pitch: The program automatically calculates the nesting result, and shows the current pitch of blank on strip according to the adjusted blank position and cut-off profile shape.

 

Width: The program automatically calculates the nesting result, and shows the current width of blank on strip according to the adjusted blank position and cut-off profile shape.

 

Utilization: The program automatically calculates the current utilization of blank nesting according to the adjusted blank position and cut-off profile shape.

 

The user is also allowed to adjust the blank and cut-off profile directly in the view area. Click on the Position button and the view area is illustrated in Figure 7.5.33. There are green feature points labeled in the center of blank, pitch, width and the side length of cut-off profile. Moving the mouse cursor to the feature point, the program will show the translation and rotation arrows near the cursor for the user to adjust the blank and cut-off profile shape directly. The user can also adjust them through manual adjustment buttons in the Position dialog box. No matter which adjustment method is selected, the current values of the corresponding parameters will be displayed in the position dialog box during adjustment.

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Figure 7.5.33  Trapezoid nesting result

RECORD

this function enables the user to record the maximum value of utilization calculated from the adjusted nesting results. Besides the maximum utilization, the program will also save the corresponding blank position and cut-off profile shape. Clicking record button, the program will automatically show the nesting result for the maximum utilization in view area and the dialog box.

 

Apply

After the adjustment of blank position and cut-off profile, click this button to perform nesting calculation. In the initial nesting calculation, only the SLAVE blank is adjusted and the angle and position of the MASTER blank remain still. After clicking the APPLY button, the master blank rotates a certain angle and the optimal position with the slave blank group is calculated. The calculated utilization may not be the greatest one.

When using One-up nesting and fitting blank outline nesting, this button is disabled. Click the OK button to confirm the nesting result and exit the position dialog box.

 

7.5.6.3  TWO-PAIR NESTING

This function enables the user to generate nesting layout with two identical blanks with opposing orientation. The setting of Setup and Constraint in this function is similar to those described in the Two-Up Nesting. Refer to Sections 7.5.6.1 and 7.5.6.2 for description about all related parameters.

7.5.6.4  MIRROR NESTING

This function enables the user to generate nesting layout by mirroring the original blank. The mirrored blank is symmetrical about X or Y direction. The setting of Setup and Constraint in this function is similar with that in the Two-Pair Nesting. Refer to Sections 7.5.6.1 and 7.5.6.2 for description about all related parameters.

 

7.5.6.5  MULTI BLANKS NESTING

This function enables the user to generate nesting layout using more than one blank outline. When defining  the blank outline, the user should click OK button or the middle button to accept each profile selection after selecting other blank outline. When all the blank outlines are selected, the user can click OK button or the middle button to exit the SELECT LINE dialog box. The other setup operations are similar to the one of One-up nesting and Two-up nesting.

 

In this function, the Blank Position is different from the one in One-up nesting and Two-up nesting, as illustrated in Figure 7.5.34. In Multi Blanks function, the Master Group is activated to enable the user to select one or more than two (including two) parts as the master blank. The master blank is mainly used to control the step size during nesting. Therefore, we usually select the blanks with greater size as the master blanks.

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Figure 7.5.34  Blank Position dialog box

MASTER GROUP

This function enables the user to select one or more than two parts from the defined outlines and add them to the master group. For multiple blanks nesting, the user is allowed to select two or more than two parts to add to the master group, and the other parts are slave parts. During nesting, we usually select the parts with greater size as the master parts. By default, the parts with greater size will be added to the list automatically.

NOTE: After entering the Position option, since the program uses the defined X-Y and Angle steps to calculate nesting layout in auto nesting, the user may use the default parameters to avoid long calculation time. These parameters can be reduced gradually to obtain more accurate nesting result.

 

ADD add

This function enables the user to select parts to add to the master group list. Click this button, the Select Blank dialog box illustrated in Figure 7.5.35. The user may select any part to add to the group list and the selected part is highlighted. The other parts are displayed in the part drop-down list as slave parts.

7-5-34

Figure 7.5.35  Select blank dialog box

DELETE delete

This function enables the user to delete parts from the list. Select parts in the list, and click this icon to delete the parts directly from the list. The removed parts will be used as slave parts for nesting calculation.

 

SELECT BLANK

This function enables the user to select master and slave blanks respectively, to perform operations such as translation, rotation and mirroring, and adjust the position between blank nesting manually during multiple parts nesting. Once a blank is selected, the outline of this blank turns to grey. Refer to Two-up nesting for  a detailed description about this function.

MANUAL

This function enables the user to manually position the blanks through translation, rotation and/or mirroring.

APPLY

Once the manual adjustment of nesting is setup, click this button to perform nesting. After adding the master parts, the program will automatically perform nesting calculation on the master parts, and insert the slave parts for calculation. Click the OK button to confirm the nesting result and exit.

In addition, for Multi Blanks Nesting, the master blank is not rotated by default in order to save the calculation time. The slave blank rotates about itself and translate towards the master blank. The program will automatically find a result with the maximum material utilization from all the calculation values.

If the user rotates the master blank, the master blank is rotated during nesting calculation in order to obtain the optimized nesting result. However, the calculation time will increase accordingly.

 

7.5.6.6  RECTANGLE NESTING 7_5_rect

In the practical nesting process, besides the above mentioned nesting methods, there are five other methods added in eta/DYNAFORM: Rectangle Nesting, Parallel Nesting, Isosceles Trapezoid Nesting, Trapezoid Nesting, and Arc Nesting.

Rectangle Nesting enables the user to generate the nesting result by embedding the blank in rectangle. Refer to One-up Nesting and Two-up Nesting for a detailed description about parameter setup and operations. The options of blank position are different with the ones of the above mentioned nesting methods, as illustrated in Figure 7.5.36.

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Figure 7.5.36  Rectangle position dialog box

Since the cut-off profile is used to fit the blank, the master and slave blanks are not considered here. In the cut-off profile nesting, Select Blank option is disabled and only the rotation buttons are enabled for the user to adjust the blank position.

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Figure 7.5.37  Rectangle nesting result page

After the user estimates the part outline (MSTEP), selects the rectangle nesting type, and performs the nesting calculation on the outline, the result page is illustrated in Figure 7.5.37. The Calculate Addendum button is available now.

Click Position button to scale Pitch, and the screen window is illustrated in Figure 7.5.38. The black line in the figure indicates the 2D outline after the pitch is scaled. Click OK button to accept the result and exit the Position dialog box. The Calculate 3D Trim Line button is enabled, as illustrated in Figure 7.5.39.

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Figure 7.5.38  Adjustment result

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Figure 7.5.39  The result after pitch scaling

Calculate 3D Trim Line

Select one result of the nesting calculation, and click Calculate 3D Trim Line button. The program will automatically project the adjusted 2D line onto the 3D product part. The user can view the 3D projection line on the part after exiting the Nesting dialog box.

Calculate Addendum

Click Calculate Addendum button to display the dialog box illustrated in Figure 7.5.40.

   Compensating Rate

   Compensating rate is used to calculate a coefficient of addendum, and the default is 0.8. The user is allowed to modify the value, or edit the default in Default Config.

   Addendum

   The program can automatically calculate an appropriate addendum according to the current nesting result (nesting utilization) and compensating rate. The user is not allowed to modify the addendum value.

Click Apply button to obtain an appropriate Addendum value. Click Exit button to exit this dialog box. The program will automatically put the calculated addendum on the Setup page for the user to redo the nesting calculation according to this addendum.

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Figure 7.5.40  Calculate addendum dialog box

7.5.6.7  PARALLEL NESTING 7_5_para

This function enables the user to generate the nesting result by embedding the blank in parallelogram. Refer to the above sections for a detailed description about parameter setup and operations. The Blank Position option is different from the one in the previous nesting methods, as illustrated in Figure 7.5.41.

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Figure 7.5.41  Blank position dialog box

The Select Blank option is disabled and only the rotation buttons are enabled. The L Angle option allows the user to perform adjustment.

 

7.5.6.8  ISOSCELES-TRAPEZOID NESTING 7_5_tap

This function enables the user to generate the nesting result by embedding the blank in isosceles trapezoid. Refer to the above sections for a detailed description about parameter setup and operations.

 

7.5.6.9  TRAPEZOID NESTING 7_5_ge-tap

This function enables the user to generate the nesting result by embedding the blank in trapezoid. Refer to the above sections for a detailed description about parameter setup and operations. The Blank Position option is different from the one in the previous nesting methods, as illustrated in Figure 7.5.42.

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Figure 7.5.42  Blank position dialog box

The Select Blank option is disabled, and only the rotation buttons are enabled. The L Angle and R Angle option allow the user to perform adjustment.

 

7.5.6.10                      ARC NESTING 7_5_arc

This function enables the user to generate the nesting result by embedding the blank in arc. Refer to the above sections for a detailed description about parameter setup and operations. The Blank Position option is different from the one in the previous nesting methods, as illustrated in Figure 7.5.43.

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Figure 7.5.43  Blank position dialog box

The Select Blank option is disabled, and only the rotation buttons are enabled. The Radius option allows the user to perform adjustment.